Machine for manufacturing thermoplastic tubes

ABSTRACT

The machine of the present invention is a means for manufacturing thermoplastic tubes from hollow thermoplastic sleeves by a variety of different manufacturing processes. The machine is a single apparatus having an indexing table with a plurality of mandrels for holding hollow thermoplastic sleeves for the purpose of transporting the same around a closed manufacturing path. The manufacturing path of the machine of the present invention is a series of stations which are mechanical devices for carrying out the manufacturing steps necessary to produce tubes from thermoplastic blank sleeves. The stations of the manufacturing path are modular so that they may be removed, added or rearranged; may be optionally connected to a process logic controller and may optionally have sensors for information feedback to the PLC device.

CROSS REFERENCE TO RELATED APPLICATIONS

[0001] This application is related to three co-pending applications:“Method for Manufacturing Thermoplastic Tubes” filed even date herewithin the names of Ronald E. Kieras and John J. Rhoades; “Process ControlMethod for a Machine for Manufacturing Thermoplastic Tubes” filed evendate herewith in the names of Ronald E. Kieras, John J. Rhoades andThomas A. Frazier; and “Plant for Manufacturing and PackingThermoplastic Tubes” filed even date herewith in the names of Ronald E.Kieras and John J. Rhoades which applications are assigned to theassignee of the present application and incorporated by referenceherein.

FIELD OF THE INVENTION

[0002] The present invention is a machine for manufacturingthermoplastic tubes from thermoplastic sleeves.

BACKGROUND OF THE INVENTION

[0003] The machinery commonly used today for making finished, headedthermoplastic tubes from 2 to 10 inches in length and from ½ inch to 3inches in diameter comprises a series of machines arranged linearly andhaving a total process line length of about 80 to 100 feet and a totalheight of about 20 to 30 feet. Process lines of such dimensions arehoused in factories often having several acres of floor space.

[0004] A conventional process line for producing a single type ofthermoplastic tube in today's manufacturing plants includes machines forheating raw polymer material into molten plastic; extruding the moltenplastic through a die to form an extruded, stretched hollow body;cooling and then cutting the hollow body into sleeves of equal lengths;transporting the sleeves to a machine for molding a head on one end ofthe sleeves to form headed tubes; transporting the headed tubes toanother machine for decorating or applying a graphic to the headedtubes; transporting the printed tubes to yet another machine forapplying a coating; transporting the printed tubes to a differentmachine for applying a cap to the headed end of the tubes andtransporting the capped tubes to a final machine for unloading the tubesfrom the process line. The removed tubes are then packed for inventoryor shipment. Such a process line requires at least four workers duringoperation, with one worker at the extrusion machine, at least twoworkers along the line to monitor the tube conveyors and other variousmachines and a final worker to pack the finished tubes at the end of theline.

[0005] Increasing size has dominated production equipment design in aneffort to take advantage of economies associated with large size. Aconventional process line can simultaneously handle several hundredtubes in different stages of production. While some productionadvantages can be achieved by large size, many limitations exist, evenin view of the giant size of the machinery.

[0006] Conventional process lines have inherent manufacturinginefficiencies dictated by several factors such as those associated withthe line machinery itself namely: large scale, mechanical operation, andprocess limitations as well as other inefficiencies like unit costlimitations. Manufacturing inefficiencies, like those described below,are serious barriers which ultimately can limit the varieties of tubesavailable in the market.

[0007] Large scale processing machines have land, capital, and laborrequirements, the costs of which are high. Additionally, large scaleequipment is complex and as a result it requires more labor and higherskilled labor to operate and maintain. Most importantly, large scaledesign does not necessarily improve total efficiency. While productioncapacity may be increased, it may be done at the cost of efficiency.Complex machines require a significant amount of capital, time and laborinput which can mean low overall efficiency when compared to the output.

[0008] The mechanical operation of conventional line machinery can addinefficiency to the manufacturing process. Process line down-time isinevitable because of the mechanical constraints of current machinery.For example, about 70% to 80% of line down-time is attributable to thetube and sleeve conveyor systems. One process line will have severaltransport systems, each system typically being a long chain with tubeholding mandrels spaced every couple of inches, wrapped around manydrive gears. These chain systems easily become jammed, frequentlydeliver improperly positioned articles to the process machinery andoften need to be stopped for adjustment and resetting. As a result ofstopping one transport system, the entire manufacturing line must beshut down.

[0009] Line down-time results in production loss. If one of theprocessing machines on the line malfunctions on the night shift, forexample, when an engineer is not available to correct the problem, theentire line will be stopped and it will remain idle until morning. Thisloss is inefficient and costly to a manufacturer.

[0010] The inflexibility of the production equipment creates inherentconstraints on the manufacturing process. Line equipment cannot easilybe rearranged to effectuate different manufacturing processes becausethe individual machines weigh several thousands of pounds and are notreadily mobile. Furthermore, large scale machines are built for a singlepurpose and are limited to that purpose. For example, offset printingmachines are limited to printing articles by the offset printing method.Thus the arrangement of production equipment limits the number ofprocessing methods available to a manufacturer.

[0011] Process control for monitoring and controlling the quality ofeach individual tube product is not commercially available for adaptionto current machinery. For example, there is no known practical way toidentify, monitor and track defective products during the manufacturingprocess. Defective products are removed only at the end of the line.When a defect occurs on a tube at the beginning of the line, continuedprocessing of that tube is inefficient since the tube will eventually bediscarded.

[0012] Because an 80 to 100 foot tube production line requires at leastfour laborers per shift, has a predictable defect rate, requires time toretool for each job and costs money even to remain idle, it creates ahigh manufacturing cost that can only be lowered by large productionjobs. It is a waste of resources to manufacture small numbers of tubeson such large machinery because the manufacturing cost per tube is toohigh. Conventional process lines can be limited to certain sizemanufacturing jobs in order to recapture manufacturing costs.

[0013] While the output of a single machine of the present inventiondoes not compare to the production capacity achieved by one conventional80 to 100 foot processing line, if the output of one simple efficientmachine is multiplied by the use of a series of such machines, then thetotal output of the series of machines can rival the conventionalprocess lines. Thus, where efficiency is maximized and multiplied, agreat number of thermoplastic tubes may be produced.

OBJECTS OF THE INVENTION

[0014] It is the principle object of the invention to provide a machinefor manufacturing thermoplastic tubes that more efficiently uses land,labor and capital, as compared to conventional manufacturing machines.

[0015] It is an object of the present invention to provide a flexiblemachine for manufacturing thermoplastic tubes to accommodate differentmanufacturing process methods.

[0016] It is a another object of the present invention to provide amachine for manufacturing thermoplastic tubes which can mark, identify,index and track every thermoplastic article being handled.

[0017] It is still another object of the present invention to provide amachine for manufacturing thermoplastic tubes which can be associatedwith other similar machines of the present invention.

[0018] It is yet another object of the present invention to provide amachine that provides an operating environment substantially free ofcontaminants, such as dirt and dust, for manufacturing thermoplastictubes suitable for the pharmaceutical industry.

[0019] It is a further object of the present invention to provide amachine for manufacturing thermoplastic tubes of improved quality.

[0020] It is yet a further object of the present invention to provide amachine for manufacturing thermoplastic tubes which can manufacturelarge numbers of tubes as well as small numbers of tubes at similaroperational costs.

[0021] It is still a further object of the present invention to providea machine for manufacturing thermoplastic tubes which can be operablyassociated with a programmable logic controller.

[0022] It is a specific object of the present invention to provide amachine for manufacturing thermoplastic tubes which can monitor andconfirm the integrity of each manufacturing process step.

[0023] It is another specific object of the invention to provide asingle machine for the production of thermoplastic tubes which can fitinto a 4×4 foot area.

[0024] Other objects, features and advantages of the present inventionwill become apparent from the following detailed description taken inconjunction with the accompanying drawings.

SUMMARY OF THE INVENTION

[0025] The machine of the present invention manufactures thermoplastictubes from thermoplastic sleeves by a variety of different processmethods. The machine has an indexing device with a plurality of mandrelsfor holding thermoplastic sleeves for the purpose of transporting thesame around a closed manufacturing path. The manufacturing path of themachine of the present invention comprises a series of manufacturingstations which have mechanical devices for carrying out themanufacturing steps necessary to produce tubes from blank sleeves.

[0026] The manufacturing stations of the manufacturing path are modularso that they may be removed, added or rearranged; the stations may beoptionally connected to a programmable logic controller (PLC) and mayoptionally have sensors for information feedback to the PLC device. Theflexibility to add, remove or rearrange manufacturing stations gives themachine of the present invention the capacity to carry out a variety ofdifferent manufacturing process methods for making thermoplastic tubes.Further, with the addition of at least one PLC device, the machine canbe operated by feedback control and can be associated with other similarmachines.

[0027] The machine of the present invention overcomes the aforementioneddisadvantages of the conventional process lines for manufacturingthermoplastic tubes. The machine is itself more mechanically efficientthan a conventional process line. For example, it utilizes a singleindexing device, a few feet in diameter at its maximum, which serves thesame purpose as the 100 foot or longer transportation system ofconventional process lines. The machine has modular manufacturingstations which can be added, removed or rearranged to create a varietyof different manufacturing processes and the stations are simplistic indesign which lowers the necessary capital and labor inputs. Furthermore,accurate process control may be added to the machines which createslabor savings, improves efficiency and reduces product waste.

BRIEF DESCRIPTION OF THE DRAWINGS

[0028]FIG. 1 is a schematic view of a machine of the present inventionof a first embodiment having a PLC device;

[0029]FIG. 2 is a schematic view of a single prior art process line formanufacturing thermoplastic tubes;

[0030]FIG. 3 is a schematic view of an arrangement of threemanufacturing machines of the present invention for manufacturingthermoplastic tubes;

[0031]FIG. 4 is a schematic view of the machine of the first embodimentwithout the PLC device, shown only with an indexing table, holdingmandrels, and a mounting ring for mounting manufacturing stations;

[0032]FIG. 5 is a schematic view from the rear of the machine of FIG. 4.

[0033]FIG. 6 is a schematic view of a housing for seating a holdingmandrel in an indexing table;

[0034]FIG. 7 is a schematic view of a machine of the first embodimentwithout the PLC device shown with supply and removal means;

[0035]FIG. 8 is a schematic view of the machine of the first embodimentwithout the PLC device shown from a lower perspective;

[0036]FIG. 9 is a schematic view of the machine of the first embodimentshown from the front with various stations identified;

[0037]FIG. 10 shows the relative locations of fourteen differentmanufacturing stations located around the circumference of an indexingtable, comprising a second embodiment of the machine of the presentinvention;

[0038]FIG. 11 is a schematic view of an indexing table and the fourteenmanufacturing stations of FIG. 10;

[0039]FIG. 12 is a schematic view of a load station;

[0040]FIG. 13 is a schematic view of a preheat station or heat station;

[0041]FIG. 14 is a schematic view of a heating probe of the preheat orheat stations shown in FIG. 13;

[0042]FIG. 15 is a schematic view of a mold station;

[0043]FIG. 16 is a cross-sectional view of a mold die used in the moldstation of FIG. 15;

[0044]FIG. 17 is a schematic view of a treat station;

[0045]FIG. 18 is a schematic view of a label station;

[0046]FIG. 19 is a schematic view of a print station;

[0047]FIG. 20 is a schematic view of a cure station;

[0048]FIG. 21 is a schematic view of a coat station;

[0049]FIG. 22 is a schematic view of a tab seal station;

[0050]FIG. 23 is a schematic view of a cap station;

[0051]FIG. 24 is a schematic view of a torque station;

[0052]FIG. 25 is a schematic view of an unload station;

[0053]FIG. 26 is a schematic view of a sonic welding station;

[0054]FIG. 27 shows the locations of twenty manufacturing stations alongthe edge of an indexing table, with each manufacturing stationassociated with a PLC device, which is a third embodiment of the presentinvention;

[0055]FIG. 28 is a schematic view of the twenty manufacturing stationsof FIG. 27;

[0056]FIG. 29 is a schematic view of an inspection station;

[0057]FIG. 30 is a schematic view of a confirmation station;

[0058]FIG. 31 is a schematic view of a reject station;

[0059]FIG. 32 is a schematic view of the machine of a fourth embodiment;

[0060]FIG. 33 is a schematic view from the front of the machine of FIG.32;

[0061]FIG. 34 is a schematic view of a machine of a fifth embodiment;

[0062]FIG. 35 is a schematic view from the front of the machine of FIG.34;

[0063]FIG. 36 is a schematic view of a machine of a sixth embodiment;

[0064]FIG. 37 is a schematic view from the front of the machine of FIG.36;

[0065]FIG. 38 is a schematic view of a machine of a seventh embodiment;

[0066]FIG. 39 is a schematic view of a machine of an eighth embodiment;

[0067]FIG. 40 is a schematic view of a machine of a ninth embodiment;

[0068]FIG. 41 is a schematic view from the front of the machine of FIG.40;

[0069]FIG. 42 is a schematic view of a machine of a tenth embodiment;

[0070]FIG. 43 is a schematic view from the front of the machine of FIG.42;

[0071]FIG. 44 is a schematic view of a machine of an eleventhembodiment;

[0072]FIG. 45 is a schematic view from the front of the machine of FIG.44;

[0073]FIG. 46 is a schematic view of one embodiment of an indexing drum;and

[0074]FIG. 47 is a schematic view of a machine of the present inventionwith an indexing drum as the indexing device.

DETAILED DESCRIPTION

[0075] I. Organization

[0076] This specification is organized into the following sections:

[0077] I. Organization

[0078] II. Introduction

[0079] 1) Conventional Manufacturing Machinery

[0080] 2) The Machine of the Present Invention

[0081] III. Manufacturing with a Machine of the Present Invention

[0082] 1) Loading Thermoplastic Sleeves

[0083] 2) Forming a Head on Thermoplastic Sleeves

[0084] 3) Decorating Thermoplastic Tubes

[0085] 4) Finishing Thermoplastic Tubes

[0086] 5) Unloading Thermoplastic Tubes

[0087] 6) Additions and Alternatives

[0088] 7) Large Scale Manufacturing

[0089] IV. Manufacturing with a Programmable Logic Controller

[0090] V. Manufacturing Example

[0091] VI. Further Embodiments

[0092] The machine of the present invention, the method of manufacturingwith the machine and the process control of the machine are summarizedin the Introduction. Next the machine and method of manufacturing aredescribed in detail as the machine and method would be utilized tomanufacture thermoplastic tubes from thermoplastic sleeves.Manufacturing with a programmable logic controller is described followedby a manufacturing example and further embodiments of the machine of thepresent invention.

[0093] II. Introduction

[0094] The machine of the present invention manufactures thermoplastictubes from thermoplastic sleeves by a variety of different processmethods. The machine is a single apparatus having an indexing devicetransportation means, i.e) an indexing table or indexing drum, with aplurality of mandrels for holding hollow thermoplastic sleeves for thepurpose of transporting the same around a closed manufacturing path. Themanufacturing path of the machine of the present invention comprises aseries of stations which have mechanical devices for carrying out themanufacturing steps necessary to produce thermoplastic tubes fromthermoplastic sleeves.

[0095] A tube, as the term is used herein, refers to any thermoplasticsleeve having at least a head on one end. A sleeve, as the term is usedherein, is a hollow body of a discrete size of any shape. A sleeve maybe fabricated from a sheet, extruded in sleeve form, or made by anyother known means. The sleeves used in the present invention arepreferably cut from an elongated longitudinally stretched and extrudedthermoplastic hollow cylinder.

[0096] The thermoplastic tubes produced according to the present methodcan be formed from various thermoplastic materials. Such thermoplasticmaterials include, but are not limited to, high density polyethylene,low density polyethylene, polypropylene, a polyester such aspolyethylene terephthalate, polycarbonates, polyvinyl chloride, and thelike.

[0097] Thermoplastic tubes may also be formed from multi layers orlaminates of various plastic materials, such as a layer of anoxygen-impermeable material comprising a polyamide such as nylon, orethylene polyvinyl alcohol, a polyvinylidene chloride or the likesandwiched between two polyethylene outer layers. Also, five layercomposites comprising an outer layer and an inner layer of athermoplastic such as polyethylene, polypropylene, a polyester such aspolyethylene terephthalate, an intermediate layer of anoxygen-impermeable material, and adhesive layers between theoxygen-impermeable material and the outer and inner layers ofthermoplastic to bond the same, can be used to form thermoplastic tubesaccording to the present method.

[0098] Thermoplastic tubes are formed from a flexible material and arereadily squeezable and collapsible to force the contents of the tube outof an orifice formed in the end of the tube at the head portion. Theyare generally of a size having a wall thickness of the sleeve portion ofbetween about 0.010 to 0.040 inch in thickness, while a shoulder and aneck portion of the tube will be thicker than the wall of the sleeve,generally between 0.035 to 0.045 inch thick. Since the tube ispreferably formed from an extruded sleeve, the wall thickness of thesleeve portion will be very uniform, with a variance in wall thicknessof the sleeve portion being only about + or −10 percent.

[0099] Preferably the extruded sleeve from which the thermoplastic tubeis formed is a sleeve cut from an extrusion which has a wall thicknessin the molten state preferably two to three times the wall thickness ofthe final cooled extruded thickness. The extrusion from which the sleeveis cut can be of any shape. Consequently, the sleeve cut from theextrusion can take the shape of the extrusion like cylindrical, oval,elliptical, rectangular or any other shape. The shape of the sleeve usedin the presents invention is typically cylindrical. Such a tubularextrusion, as is known, is formed by extruding thermoplastic materialfrom an extrusion annulus in a molten state and stretching the hottubular form, in the direction of the longitudinal axis, into a tube orsleeve having a wall thickness one-half (½), one-third (⅓), or less,than the extrusion annulus. Such a stretch oriented extruded sleeve,when heated above the glass transition temperature of the thermoplasticmaterial, due to the plastic memory of the thermoplastic material, willincrease in thickness to the thickness of the molten material exitingthe extrusion annulus, and shrink in length, thus providing sufficientmolten plastic mass to form a head on the sleeve according to thepresent method. When using high density polyethylene (HDPE) or lowdensity polyethylene (LDPE), for example, the annulus would extrude atubular form of about 1.5 inch in diameter having a wall thicknessbetween about 0.040-0.046 inch, which would be stretched into a stretchoriented extruded sleeve of about 1.0 inch in diameter having a wallthickness between about 0.015-0.018 inch. The final thermoplasticsleeves used in the present invention can be of any typical diametersuch as {fraction (1/2, 5/8, 3/4, 7/8)}, 1, 1 {fraction (3/16)}, 1 ⅜, 1½ and 2 inches.

[0100] In addition to forming a head on a thermoplastic sleeve, thereare many other manufacturing process steps that may be performed on athermoplastic sleeve such as decorating, securing a cap to the headedend, marking articles with indicia, etc. All manufacturing steps areperformed by the manufacturing stations located around the closedmanufacturing path.

[0101] The stations of the manufacturing path of the present machine aremodular so that they may be removed, added or rearranged; the stationsmay be optionally connected to a programmable logic controller (PLC) andmay optionally have sensors for information feedback to the PLC deviceand feedback process control. The flexibility to add, remove orrearrange manufacturing stations gives the machine of the presentinvention the capacity to carry out a variety of different manufacturingmethods for making thermoplastic tubes.

[0102] The configuration of the machine of the present invention i.e.)the configuration of the indexing device, manufacturing path andoptional PLC device, depends on the desired tube to be produced. If onlya simple tube is desired than the machine may be configured with theminimum stations necessary, namely a load station; a station for forminga head; and an unload station. Such a machine may also be appropriate ifthe sleeves are previously decorated or preprinted and only themanufacturing of a head is desired. If a decorated tube with a capsecured to the headed end is desired then the machine can be arrangedwith additional stations for decorating and securing a cap to the tube.

[0103]FIG. 1 illustrates a machine 1 of the present invention of a firstembodiment having a indexing table 3 rotatable in a predetermineddirection and housed in a frame 5 and mounted, by mounting bolts 7, on afixed shaft 61 (FIG. 5) associated with an indexer 63 (FIG. 5). Indexingtable 3 has a plurality of mandrels 9 mounted thereon for holdingthermoplastic sleeves.

[0104] Adjacent each mandrel 9 on machine 1 is a manufacturing station11, mounted on a mounting ring 13, for performing a process step on asleeve mounted on each mandrel 9. The configuration of manufacturingstations 11 on mounting ring 13 comprises the manufacturing path. Themanufacturing path is closed or endless because the first station in thepath is adjacent to the last station in the path. All sleeves aretransported around the manufacturing path by the indexing table 3. Allmanufacturing stations 11 of the manufacturing path may be connected toa PLC device 15, as shown by the dashed lines. Indexing table 3 rotatesrelative to the manufacturing stations 11. A base plate 17 with aplurality of leveling legs 19 supports frame 5. In anotherconfiguration, PLC device 15 may be housed on base plate 17.

[0105] The embodiments shown and described herein describe a machine ofthe present invention, a method of manufacturing with the machine and aprocess control of the machine. The embodiments do not intend toencompass every possible variation, configuration and combination of themachine, method of manufacturing, and process control within the scopeof the present invention. Other embodiments will be apparent to thoseskilled in the art.

[0106] 1) Conventional Manufacturing Machinery

[0107] There is shown in FIGS. 2 and 3 a schematic view of the relativelengths of a conventional process line (FIG. 2) which is between 80 and100 feet long and an arrangement of three machines of the presentinvention, about 30 feet long in length associated with a commonconveyor (FIG. 3). Each arrangement in FIGS. 2 and 3 includes onemachine for extruding a hollow thermoplastic body and cutting the bodyinto thermoplastic sleeves of equal lengths.

[0108] In the conventional manufacturing process, the thermoplasticsleeves travel along a path 80 to 100 feet in length where the sleeve isformed into a thermoplastic tube which can be decorated, sealed withprotective material and capped. Conversely, with only a single machineused in a plant of the present invention, a thermoplastic sleeve isloaded onto the machine whereby it travels around a closed path only afew feet in length where the sleeve is formed into a thermoplastic tubewhich may also be decorated, protective sealed and capped on the samemanufacturing path.

[0109] Referring to FIG. 2, the machine 21 for extruding, cooling andcutting thermoplastic sleeves is followed by a loading machine 23 whichloads thermoplastic sleeves onto a transportation belt 25 whichtransports the sleeves to a machine 27 for forming a head on one end ofthe sleeves. The resulting headed thermoplastic sleeves, which are nowconsidered as thermoplastic tubes, are transported by a system 29 to aprinting machine 31 for decorating the exterior of the thermoplastictubes. The decorated thermoplastic tubes are then transported by aconveyor 33 to a capping machine 35 where a cap is snapped or screwedonto the headed end of the thermoplastic tubes. Finally, the capped tubeis unloaded from the process line by an unloader 37 and transported by aconveyor 39 to a packing machine 41, where the tubes are packed forshipment.

[0110] By comparison, an arrangement of three machines 43, 45 and 47 isshown in FIG. 3. The arrangement includes a machine 49 for extruding,cooling and cutting thermoplastic sleeves followed by a loading machine51 for loading thermoplastic sleeves onto a conveyor system 53. Thesleeves travel down conveyor system 53 where they are loaded onto one ofthe three machines 43, 45 and 47 by mechanical feeders 55, 57 and 59.Machines 43, 45 and 47 transport the sleeves around a closed path only afew feet in length where the sleeves are transformed from blank sleevesinto finished thermoplastic tubes by the action of several manufacturingstations located around the closed path.

[0111] The machine of the present invention uses significantly lesssleeve and tube handling transfers compared to conventional tubemanufacturing machines. This reduction, due in part to the compactnessof the manufacturing path on the machine, improves efficiency andreduces the cost and time of the tube manufacturing process. In fact,the total time of manufacturing from resin pellet to finished tube is afew minutes as compared to at least a half an hour on conventionalmachinery. The machine of the present invention may be built to fit in a4×4 foot area.

[0112] 2) The Machine of the Present Invention

[0113] FIGS. 4-9 illustrate, in greater detail, machine 1 of the firstembodiment that may be used as one of machines 43, 45 and 47 shown inarrangement in FIG. 3. FIG. 4 shows mandrels 9 of machine 1, shownwithout PLC device 15. Mandrels 9 are evenly spaced on indexing table 3.Indexing table 3 is typically a circular plate. While the preferredembodiment of indexing table 3 is an aluminum plate, indexing table 3may be substituted by any other means which transports sleeves around aclosed manufacturing path.

[0114] The manufacturing stations 11 of the closed manufacturing path(FIG. 1) are mounted and arranged on a support, such as mounting ring 13(FIG. 4). Mounting ring 13 supports manufacturing stations 11 in aposition such that manufacturing stations may perform a process step ona sleeve or tube on mandrel 9. In the embodiment in FIG. 1, mountingring 13 supports manufacturing stations 11 so that they are adjacent toand in front of a corresponding mandrel 9. Alternatively, stations 11could be mounted on a frame (not shown) in the same plane as indexingtable 3 so that manufacturing stations are beside a correspondingmandrel 9.

[0115]FIG. 5 is a perspective view from the rear of machine 1 of FIG. 4,showing indexing table 3 connected to a shaft 61 rotatably mounted on anindexer 63. Indexer 63 may be conveniently mounted on frame 5.

[0116] Indexer 63 is a means for rotating or advancing indexing table 3in a step-wise or incremental manner so that sleeves loaded ontomandrels 9 stop at each manufacturing station of the closed path for atime period long enough to effectuate a manufacturing process step.Indexing table 3, of this embodiment, rotates counterclockwise.

[0117]FIG. 6 illustrates a housing assembly 65 for mandrel 9 on indexingtable 3 of machine 1. Housing assembly 65 at the base of mandrel 9allows mandrel 9 to rotate smoothly at various speeds, which isnecessary for certain manufacturing steps. Inside housing assembly 65are two rings 67 and 69 of ball bearings separated by a bearing spacer71. A bearing clamp 73 is also added to housing assembly 65 for support.At one end of mandrel 9 is mounted a mandrel pulley 75 for improvedweight distribution and a means to rotate mandrel 9. The desirablehousing assembly 65 materials are durable materials, such as metal,because the components of housing assembly 65 wear.

[0118]FIGS. 7 and 8 show perspective views of machine 1. FIG. 7 showsmachine 1 with pickle sorter 77 which supplies sleeves directly to loadstation 79. FIG. 7 also shows unload chute 81 which transports tubesfrom machine 1 that have been removed by unload station 83 from indexingtable 3. FIG. 8 shows, in greater detail, the relative locations of loadstation 79, unload station 83 and the remaining manufacturing stations.

[0119] To make machine 1 operable, machine 1 must be connected to apower source and other additional input sources as necessary, such ascompressed air, water, electricity, steam, heated air, etc. Inadditional to supplying sleeves to machine 1, other raw materials suchas caps, formed heads, etc. may be necessary for the manufacturingprocess.

[0120]FIG. 9 schematically shows the configuration of the 12manufacturing stations 11 of machine 1, all connected to PLC device 15.The manufacturing stations and corresponding manufacturing process stepsshown are: (A) load, (B) preheat, (C) heat, (D) mold, (E) treat, (F)print, (G) cure, (H) coat, (I) cure, (J) cap, (K) torque and (L) unload.

[0121] The minimum process steps necessary to form a tube from a sleeveare: loading the sleeve on the machine, forming a head on the sleeve,and unloading the headed sleeve. Besides the minimum steps, many otherfinishing or intermediate steps may be performed by additionalmanufacturing stations to produce a product of higher complexity.

[0122] For example, machine 85 a second embodiment of a machine of thepresent invention represented schematically in FIG. 10, has 14 stationslocated adjacent to each of 14 mandrels 87 mounted on indexing table 89,which rotates counterclockwise via indexer 91 (FIG. 11) in thisembodiment. The 14 different stations and corresponding process stepsare as follows: (A) load, (B) preheat, (C) heat, (D) mold, (E) treat,(F) label, (G) print, (H) cure, (I) coat, (J) cure, (K) tab seal, (L)cap, (M) torque and (N) unload.

[0123]FIG. 11 is a perspective view of machine 85 of FIG. 10, showingpartial illustrations of manufacturing stations (A) through (N). Machine85 has three different decorating stations, (F) label, (G) print and (I)coat. It is unlikely that a manufacturing process would employ all threestations. Typically, only one or two of the decorating stations would beoperable. Non-operable stations may be turned off manually or by a PLCdevice or they may be removed.

[0124] III. Manufacturing with a Machine of the Present Invention

[0125] Again the configuration of the indexing device, manufacturingpath and optional PLC device, depends on the desired tube to beproduced. A decorated, sealed and capped tube will be produced usingmachine 85, a second embodiment of a machine of the present invention,illustrated in FIGS. 10 & 11 having 14 stations. All 14 manufacturingstations belonging to machine 85 are described below.

[0126] Each manufacturing station comprises a device for performing amanufacturing step and a means for mounting the device on a support orframe, like mounting ring 13 of FIG. 1. The mounting means may include aportion which is adjustable, like an X-Y positioning table, so therelative location of the device to the sleeve holding mandrel may bechanged. The adjusting may be done manually or optionally by PLCcontrol. The manufacturing stations operate continuously and may becoordinated with the rotation of the indexing device.

[0127] The manufacturing stations of the second embodiment shown in FIG.11 may be grouped into five general process steps: 1) Loading, 2)Forming a Head, 3) Decorating, 4) Finishing and 5) Unloading. As will bedescribed below there are many ways to effectuate the manufacturingprocess steps to create decorated, sealed and capped tubes.

[0128] 1) Loading Thermoplastic Sleeves

[0129] After transporting sleeves to a machine of the present inventioneach sleeve is loaded on a mandrel on the indexing device at a loadstation. The load station comprises a loading device that can load asleeve onto a mandrel which is about 0.005 inch smaller in diameter thanthe sleeve, to provide a snug fit and a means to mount the loadingdevice to the frame of the machine. Preferably, the sleeve should beloaded and positioned so that one end of the sleeve extends apredetermined distance over one end of the mandrel.

[0130] The loading device may be conventional device: a pneumatic pushrod, a cam driven push rod, an advancing and retracting linear actuator,a crank motion device or a servo-motor driven push rod. The preferredloading station, a pneumatic push rod, is described below as loadstation (A).

[0131] (A) Load Station

[0132]FIG. 12 illustrates the preferred embodiment of load station (A),which loads and positions sleeves onto mandrel 87 on indexing table 89.Load station (A) comprises a pneumatic loading device and a means formounting the loading device to a frame or a mounting ring, like mountingring 13 of FIG. 1. In this embodiment, pneumatic loading devicecomprises a pneumatic push rod 93 which pushes sleeves supplied tocradle loader 95, by pickle sorter 77 as shown in FIG. 7, onto mandrel87.

[0133] Pneumatic push rod 93 is driven back and forth along cradleloader 95 by air cylinder 97, supplied with air by air lines 99,positioned behind cradle loader 95 on a mounting bracket 101. Mountingbracket 101 is further mounted on mounting plate 103 which is attachedto a mounting ring or equivalent, like ring 13 of FIG. 1.

[0134] Cradle loader 95 has a “V” shaped surface 105 for aligning thecenter axis of a thermoplastic sleeve resting on V-shaped surface 105with the center axis of mandrel 87, so the sleeve may be loaded ontomandrel 87, with a clearance as small as 0.005 inch, without damage.Cradle loader 95 is secured on mounting plate 103.

[0135] Both cradle loader 95 and air cylinder 97 are mounted on aportion of mounting plate 103 that is adjustable relative to thelocation of mandrel 87, much like an X-Y positioning table. Theadjustment may be done manually by a X-axis adjustment rod 107 and aY-axis adjustment rod 109. Alternatively the adjustment could becontrolled by a PLC device.

[0136] Load station (A) operates as follows: A sleeve is supplied toV-shaped surface 105 of cradle loader 95 from a supply means. When thecenter axis of the sleeve is aligned with the center axis of mandrel 87,push rod 93 pushes the sleeve along V-shaped surface 105 so that thesleeve loaded onto mandrel 87 and preferably positioned with a portionextending over the end of mandrel 87 so that an end is exposed.

[0137] The ideal cradle loader has a low coefficient of friction and asurface that will not mark or scratch sleeves which rest on the surface.Possible materials that have a non-marking surface with a lowcoefficient of friction are Teflon and Delrin, a type of lubricatednylon.

[0138] After sleeve is loaded onto mandrel 87, indexing table 89advances or “indexes” one position and stops again so that the loadedsleeve is adjacent to the next station downstream load station (A) inthe closed manufacturing path.

[0139] 2) Forming a Head on Thermoplastic Sleeves

[0140] In the preferred embodiment, a head is formed on the exposed endof the loaded sleeve by first heating the exposed end above the glasstransition temperature so the thermoplastic is molten and then formingthe molten thermoplastic into a head with a mold die or equivalentdevice.

[0141] In this embodiment, a single indexing device supports sleeves andtubes in a variety of different stages of manufacturing. The speed ofrotation of the indexing device is limited by the speed of the slowestmanufacturing step. In this embodiment time is conserved by dividing theheating step between two stations, a preheat station and a heat station.

[0142] Machine 85, of the second embodiment, formes a head on athermoplastic sleeve by the separate steps of preheating, heating andmolding. Three manufacturing stations are used, preheat (B), heat (C)and mold (D).

[0143] (B) Preheat Station

[0144]FIG. 13 illustrates preferred preheat station (B), locateddownstream from load station (A). Preheat station (B) heats the portionof a sleeve which extends beyond the end of mandrel 87 above the glasstransition temperature to create a molten thermoplastic mass for moldinginto a head. Preheat station (B) has a heating device secured to amovable carriage and means to mount the device and carriage to the frameof the machine of the present invention, like mounting ring 13 ofFIG. 1. The carriage brings the heating device into proximity with theexposed portion of the sleeve.

[0145] In FIG. 13 carriage 111 has a frame or housing 113 which providesa top surface 115 for securing by brackets 117 a heating device 119behind a sleeve cooling bushing 121 and an interior cavity 123, undertop surface 115, for mounting or locating a means to impart motion tocarriage 111, like an air cylinder 125. Carriage 111 is pneumaticallydriven by an air cylinder 125, supplied with air by lines 127. Carriage111 is slidably mounted on rods 129 which are linear guide means. Eachrod 129 is secured by a bracket 131 at each end of rod 129 to mountingplate 133.

[0146] Preheat station (B) operates as follows: when a sleeve loaded andpositioned on mandrel 87 is aligned with the center axis of coolingbushing 121 and heating device 119 of preheat station (B), carriage 111advances along rods 129 to bring heating device 119 in proximity to thesleeve. Carriage 111 may move by any conventional method, namely a servoor indexing motor, a pneumatic, hydraulic, electric or magneticactuator.

[0147] As carriage 111 advances, the exposed portion of the sleeveenters and passes through an orifice 135 in cooling bushing 121. Theexposed portion of the sleeve is partially inserted into heating device119. Heating probe 137 located in heating device 119 extends into theexposed portion of the sleeve. The interior surface of the exposedportion is then heated by hot air exiting small openings 139, shown inFIG. 14, at the end of heating probe 137. Air is supplied to heatingdevice 119 by supply line 141. Cooling bushing 121, which may be cooledby a water jacket (not shown), substantially prevents the heat appliedto the exposed end of the sleeve from spreading to the remainder of thesleeve.

[0148] Carriage 111 retracts by the action of air cylinder 125 to itsoriginal position, out of the path of motion of mandrel 87, after apreselected period of time. The time of heating depends on the materialand the thickness of the thermoplastic to be heated. After carriage 111retracts, the preheating step is completed.

[0149] Any means for heating an air flow in heating device 119 issatisfactory. Typically, heating device 119 is made of a metal which hasgood electrical resistance. In this embodiment, heating device 119 isitself heated so that air flowing through it is raised to the desiredtemperature. The air flow rate, the temperature of the heating elementand time of heating can all be controlled by a PLC device.

[0150] Preheat station (B) is made of light weight durable materials.For example, cooling bushing 121 may be made of aluminum and heatingelement 119 and heating probe 137 may be made of stainless steel.Aluminum provides a durable and light weight material for housing 113 ofcarriage 111. Rods 129 receive a lot of wear so they need to be made ofa durable and hard material. Ideally, rods 129 can be made from coldrolled steel.

[0151] After the heating at preheat station (B), indexing table 89advances one position so that the heated exposed end of the sleeve isnow adjacent heat station (C).

[0152] (C) Heat station

[0153]FIGS. 13 and 14 also illustrate the preferred heat station (C) ofthis embodiment. Preferably heat station (C) is physically the same aspreheat station (B). Heat station (C) operates in the same manner aspreheat station (B) and heats the preheated exposed portion of thesleeve above the glass transition temperature. Depending on the heatingtime of preheat station (B), the carriage 111 of heat station (C) (FIG.13) may move at the same rate or a different rate than carriage 111 ofpreheat station (B).

[0154] As the inside surface of the sleeve is heated close to the glasstransition temperature, in this embodiment, the inside surface meltsfaster than the outside surface. The heating of a longitudinallystretched and extruded thermoplastic sleeve results in die swelling. Dieswelling is the shrinking and thickening of a thermoplastic sleevebecause the plastic memory of the sleeve wants to return the sleeve toits original larger shape, the shape of the die used in the extrusionprocess. The molten preform mass at the heated end of the sleevethickens and is ideal for molding a head onto the end of the sleeve.

[0155] After the heating is completed carriage 111 of heat station (C)retracts out of the path of mandrel 87. Indexing table 89 advances oneposition so that the hollow thermoplastic sleeve is adjacent moldstation (D) downstream from heat station (C).

[0156] (D) Mold station

[0157]FIGS. 15 and 16 illustrate preferred mold station (D), locateddownstream from heat station (C). Mold station (D) forms a head from theheated thermoplastic mass at the end of the sleeve previously heated inpreheat station (B) and heat station (C). Mold station (D) has a molddie secured to a movable carriage and means to mount the device andcarriage to the frame of the machine of the present invention, likemounting ring 13 of FIG. 1. The carriage brings the mold die intocontact with the exposed portion of the sleeve.

[0158] In FIG. 15 carriage 143 has a frame or housing 145 which providesa top surface 147 for securing a mold die 149 and an interior cavity151, under top surface 147, for mounting or locating a means to impartmotion to carriage 143, like an air cylinder 153. Carriage 143 ispneumatically driven by an air cylinder 153, supplied with air by lines155. Carriage 143 is slidably mounted on rods 157 which are linear guidemeans. Each rod 157 is secured by a bracket 159 at each end of rod 157to mounting plate 161.

[0159] In this embodiment, mold die 149, secured by brackets 163 to topsurface 147 of carriage 143 and preferably made of aluminum or steel,has four components: a mold bushing 165, a mold bushing plate 167, athread insert plate 169 and an orifice pin bushing 171, as illustratedin cross-section in FIG. 16. Mold bushing 165 forms the entrance to molddie 149. Mold bushing 165 guides the heated sleeve into mold die 149.The subsequent components, mold bushing plate 167, thread insert plate169 and orifice pin bushing 171 shape portions of a head on the end ofthe sleeve. A die with four components, like mold die 149, allows amanufacturer to selectively shape the head of a sleeve with specificmembers to comprise mold die 149. Orifice pin bushing 171 contains aspike (not shown) located in the center to form an orifice in the headedend of the thermoplastic tube.

[0160] Alternatively the mold die may be a one-piece die which does notopen. Such a die would be useful for forming a simple head on a sleeve.The die may take the form of a simple one-piece member with a concaveface to shape the sleeve end portion of the molten thermoplastic into aclosed end of a tube. But if threads or undercuts are desired on thehead, then at least a portion of the mold die, for example, must open toallow the release of the tube once the head has been formed. Simple openand close pneumatic dies, like an air cylinder split die, are availablefor this purpose.

[0161] The time and pressure of the molding step are important. The timefor molding should be limited to the time necessary to form a head fromthe heated thermoplastic. If a head is not removed from a die onceformed, it may stick to the inner surface of the die. If the moldpressure is too great, the thermoplastic may be pressed out of the mold.If the mold pressure is weak, a head may be poorly formed and uneven.The time of molding and pressure used will depend on the thermoplasticand its thickness. Time and pressure may be controlled by a PLC device.

[0162] After a head is formed, indexing table 89 indexes to the nextstation located downstream, treat station (E).

[0163] 3) Decorating Thermoplastic Tubes

[0164] As previously mentioned there are a variety of ways to decoratethe outside surface of a thermoplastic sleeve or thermoplastic tube ifit has been so formed. The decoration step may precede the head formingstep. In this embodiment however, decoration occurs after forming a headon the sleeve.

[0165] Decorating may occur by a variety of different means and methods.For example, a label may be applied to a tube by a label dispensingdevice. A tube may be marked with an indicia, including an individualindicia or a printed graphic. Many printing methods are know forprinting indicia on tubes, such as offset printing, screen printing,foil printing, inkjet printing, letter printing, computer printing, etc.A tube may also be decorated by being coated, heat embossed or etched.

[0166] The outside surface of a thermoplastic tube or sleeve istypically treated prior to decorating by printing, coating or labellingso that the outer surface is more receptive or adherent to a printedgraphic. The type of treatment step will depend on the decoration stepthat follows.

[0167] The manufacturing stations used to decorate the thermoplasticarticle on machine 85 of the second embodiment include: treat station(E) for pretreating the thermoplastic article, label station (F), printstation (G), coat station (I) and cure stations (H) and (J).

[0168] (E) Treat station

[0169] Often before a printed indicia or label may be applied tothermoplastic polymer, the polymer must be treated to receive theprinted indicia or label. There are a variety of ways to surface treatthermoplastic, such as, flame treatment, corona treatment, ionictreatment, electrical treatment, heat treatment or chemical treatment.

[0170] Corona treating is common and works as follows: A corona treatingsystem is like a capacitor. High voltage is applied to an electrode.Between the electrode and a “ground” is a dielectric, comprised of thethermoplastic tube and air. The voltage buildup on the electrode ionizesthe air in the electrode, creating the highly energized corona. Thisexcites the air molecules, reforming them into a variety of freeradicals, which then bombard the tube surface, increasing its polarityby distributing free bond sites across it. This makes the surface morereceptive to printed indicia.

[0171] Flame treatment is common for bottles, tubing, and automotiveparts. Like corona, it induces an ionized airstream, which alters thesurface as it impinges upon it. Flame treatment is accomplished byburning an ultra-lean gas mixture, whose excess oxygen is renderedreactive by high temperatures.

[0172] Treatment, specifically corona and flame treatment, alter apolymer's surface chemistry. The presence of carbonyl and hydroxylgroups, which are absent on an untreated surfaces, enhances wetability,allowing inks, coatings, and adhesives to flow out and coat uniformly.

[0173]FIG. 17 illustrates treat station (E). Treat station (E) comprisestreatment device 173, having supply line 175, which provides the meansfor treating a thermoplastic tube located on mandrel 87. In thisembodiment, treatment device 173 is a corona treater. Treatment device173 is secured to mounting bracket 177 that is adjustable relative tothe location of mandrel 87, much like an X-Y positioning table. Mountingbracket 177 has a X-axis adjustment rod 179 and a Y-axis adjustment rod181. Mounting bracket 177 is further mounted on the frame of themachine.

[0174] (F) Label Station

[0175] In this embodiment, the first decorating station downstream treatstation (E) is label station (F). Label station (F) has a device forapplying adhesive labels to the exterior surface of thermoplastic tubesand a means to mount the device to the frame (not shown) of the machine.A device suitable for applying labels to thermoplastic tubes may be usedin label station (F). The indigo or zicon processes are preferable forlabeling on thermoplastic tubes.

[0176]FIG. 18 illustrates preferred label station (F). Label station (F)has a label dispenser 183, which dispenses sheet 185, having labelsthereon, which travels through a series of directional cylinders 187 a,b, c, d, e, and f, which are label guides, to a final label intake roll189. Sheet 185 exits dispensing device 183, travels to directionalcylinder 187 e, which is in close proximity with a tube on mandrel 87.When sheet 185 passes directional cylinder 187 e, an individual label ispinched off sheet 185 and pressed against a tube. The empty label sheet185 is rewound on label intake roll 189.

[0177] It is important that the labels are applied to tubes and not tomandrel 87. To avoid such error, a sensor can be included in labelstation (F) to detect whether a tube is located on mandrel 87.

[0178] Label station (F) is a labeling device housed in a frame 191which is mounted on a frame or mounting ring, like mounting ring 13 asshown in FIG. 1, of the machine of the present invention.

[0179] (G) Print station

[0180] Instead of applying an adhesive label to the exterior of thethermoplastic tube, a printed indicia may be applied to the tube. FIG.19 illustrates a preferred inkjet printer of print station (G) havingfour printer head cartridges 193 a, b, c and d disposed on a bar 195which is secured to mounting bracket 197, which is further mounted tothe frame (not shown) of the machine of the present invention. Printerhead cartridges 193 a, b, c and d are connected to a plurality of inksupply and control lines 199.

[0181] The inkjet printer of print station (G) is preferably controlledby a PLC device. A PLC device gives a manufacturer the ability to markeach tube with an individual indicia or the same printed graphic. A PLCdevice can control the ink flow and pattern of printing from the printerhead cartridges of an inkjet printer. A PLC device may be programmed toprint individual indicia, like a unique serial number on each tube. Thusan inkjet printer is advantageous because of the ability to quickly andautomatically alter, modify, and change printed indicia on thermoplastictubes.

[0182] After a printed indicia is applied to the tube, the printing mustbe cured.

[0183] (H) Cure station

[0184] Cure station (H), located downstream from print station (G),cures the printed indicia applied to the thermoplastic tube. FIG. 20illustrates preferred cure station (H), having a curing unit 201connected to a supply and control line 203. Curing unit 201 is securedto mounting bracket 205 that is adjustable relative to the location ofmandrel 87. Adjustment may be done manually by a X-axis adjustment rod207 and a Y-axis adjustment rod 209. Alternatively the adjustment couldbe controlled by a PLC device. Mounting bracket 205 is secured to themounting ring or equivalent of the frame of the machine of the presentinvention.

[0185] Curing unit 201 may cure the printed graphic by any known meanssuch as heat, infrared light, hot air, or ultra violet light. In theembodiment illustrated in FIG. 20, curing unit 201 is a hot air curingunit where hot air is discharged from curing unit 201 onto the tube.

[0186] Curing unit 201 may be left on continuously. Or, like otherstations in the manufacturing process, it may be computer controlled sothat the curing process may be controlled with more precision. Becausecuring unit 201 may be a UV light emitting unit, safety shutters (notshown) may be provided to shield operators from the exposure of UVlight.

[0187] (I) Coat station

[0188] The third decorating station on machine 85 is coat station (I)which is a station for applying a coat of material to a tube. This maybe an alternative to decorating via label station (F) or print station(G). Coat station (I) may also be used in conjunction with label station(F) and print station (G). FIG. 21 illustrates preferred coat station(I). Coat station (I) has two coater rollers 211 a and b in front of adoctor blade 213, all of which are supported on a mounting bracket 215further mounted on the frame of the machine of the present invention.The two coater rollers 211 a and b contact a tube on mandrel 87 andapply a chemical coat directly onto the tube. The chemical coat isapplied to coater rollers 211 a and b by doctor blade 213. Doctor bladeis connected to a chemical supply line (not shown). After a chemical isapplied on the tube the chemical coating is typically cured.

[0189] (J) Cure station

[0190] Final cure station (J) is the same as cure station (H)illustrated in FIG. 20. Final cure station (J) is for the purpose ofcuring coating or indicia on tubes and may cure by the same means ascure station (H). In the present embodiment, final cure station (J) is aheat cure station having a curing unit 201 which is a hot air curingunit where hot air is discharged from curing unit 201 onto the tube.

[0191] After decorating, the thermoplastic tube may advance through avariety of different finishing stations for finishing the decoratedtube. The number, arrangement and variety of finishing stations willdepend on the desired tube to be produced.

[0192] 4) Finishing Thermoplastic Tubes

[0193] Besides forming a head on a thermoplastic sleeve and decoratingthe same, there are many different process steps that may be performedfor finishing the thermoplastic tube. For example, the orifice on theformed head may be sealed with a protective foil, a closure means may besecured to the formed head and the closure may be torqued automaticallyfor proper tightness.

[0194] Machine 85 of FIG. 11 includes the following finishing stations:tab seal (K), cap (L) and a torque station (M).

[0195] (K) Tab Seal Station

[0196]FIG. 22 illustrates a tab seal station of the preferredembodiment. A tab sealer 217 is housed in a frame 219 comprising amounting bracket 221 on which tab sealer 217 rests connected to amounting plate 223 located on either side of the mounting bracket 221.This structure can support the remainder of the device as necessary, toplace a small protective seal, made of foil or other material, over theorifice of headed thermoplastic tubes.

[0197] A protective tab seal is added to tubes by means of a applicatordevice which, in the preferred embodiment is a tab seal punch 225 whichcuts and places appropriately sized tab seal material 227 over theorifice of a thermoplastic tube.

[0198] As shown in FIG. 22 tab seal punch 225 is driven by an aircylinder 229 supplied with air by air and control lines 231. The tabseal punch 225 slidably moves, by the action of the air cylinder 229through a tab seal die 235 on a tab seal mounting plate 237 and contactstab seal material 227 on the other side of the tab seal die 235. Thistab seal material 227 is supplied from a tab seal stock roller 239. Tabseal material 227 unwinds from stock roller 239, passes tab seal punch225 and is taken up by tab seal foil intake roller 241.

[0199] By the pneumatic action of the tab seal punch rod 225 through thetab seal die 235, small portions of tab seal material 227 are cut fromthe ribbon of tab seal material 227 and brought into contact with theheaded end of a thermoplastic tube whereby the tab seal foil is cut andsecured.

[0200] The tab seal station (K) illustrated in FIG. 22, operatescontinuously as long as it is supplied with tab seal foil stock. Topossibly accommodate longer continuous manufacturing periods, a tab sealfoil stock roller (not shown) may be mounted on top of the frame of themachine such that tab seal foil stock ribbon is wound from the foilstock roller down in front of the tab seal die to supply foil stock tothe tab seal station. This ribbon may be wound under the die and back upto a larger intake roll (not shown) mounted elsewhere on themanufacturing station. Therefore this allows for the possibility of muchlarger stock and intake rolls to accommodate larger manufacturing times.

[0201] (L) Cap Station

[0202] Cap station (L) is located downstream from tab seal station (K).This station provides a means for adding a closure or cap, typicallymade of plastic, to the headed end of a tube. The cap may be eithersnapped onto the end of the thermoplastic tube or screwed on if the headhas screw threads.

[0203] Preferable capping station (L), as shown in FIG. 23, comprises acap applicator 243 and brackets 245 for mounting cap applicator 243 tothe frame of the machine, like mounting ring 13 of FIG. 1. Capapplicator 243 is a device which secures a cap or closure to the headedend of tubes. Each cap is individually placed on the headedthermoplastic tube by cap applicator 243. If the cap must be screwed onto the head of the thermoplastic tube, then cap applicator 243 has ascrew type mechanism for rotating caps. Cap applicator 243 iscontinuously supplied with caps by a supply line (not shown). Capapplicator 243 is connected to power supply and control line 247.

[0204] After a cap is applied to the headed thermoplastic tube, thetorque of the cap is typically adjusted.

[0205] (M) Torque Station

[0206] Torque station (M) is located downstream from cap station (L).Torque station (M) is provided for adjusting the torque of the closureapplied to the head of the thermoplastic tube in cap station (L).

[0207] As illustrated in FIG. 24, torque station (M) comprises a captorque chucking device 249 and brackets 251 for mounting torque chuckingdevice 249 to the frame of the machine, like mounting ring 13 of FIG. 1.Chucking device 249 adjusts the torque of each cap on each tube. It canaccomplish this device by a mechanical screw means.

[0208] Torque station (M) is connected to power supply and control line253.

[0209] 5) Unloading Thermoplastic Tubes

[0210] Manufacturing on a machine of the present invention ends withunloading tubes from mandrels 87. To unload thermoplastic tubes offmandrels, the following devices, each comprising an unload device orstripper, may be used: a pneumatic stripper, a stripper driven by a camdriver, an advancing and retracting linear actuator stripper, a crankmotion stripper or a servo-motor driven stripper. The preferredunloading device is a pull rod stripper driven by an air cylinder whichworks similarly to push rod 93 of load station (A).

[0211] (N) Unload Station

[0212] The final station of machine 85 is illustrated in FIG. 25 asunload station (N). Unload station (N) is downstream torque station (M)and next to the first station in the manufacturing path load station(A).

[0213] Pneumatic stripper 255, with stripper plate 257, is driven backand forth along guide arm 259 by air cylinder 261, supplied with air byair lines 263, positioned behind guide arm 259 on a mounting bracket265. Mounting bracket 265 is further mounted on a mounting plate, likemounting plate 103 of FIG. 12, which is attached to a mounting ring orequivalent, like ring 13 of FIG. 1. Stripper 255 removes the finishedthermoplastic tubes from mandrel 87 by stripper plate 257 attached tothe end of stripper 255.

[0214] Unload station (N) operates as follows: a stripper plate 257slides back and forth in contact with mandrel 87 unloading any tube onmandrel 87. Once the thermoplastic tube has been removed, stripper 255and stripper plate 257 return to their original position.

[0215] All of the 14 stations described above operate to form oneembodiment of a complete manufacturing process for decorated capped andtorqued thermoplastic tubes.

[0216] 6) Additions and Alternates

[0217] The machine of the present invention is intended to be flexibleto that manufacturing stations of various types, numbers andarrangements may be configured on the machine so that a large variety oftubes can be manufactured. In addition to the stations and methodsdescribed above, many other manufacturing stations and process steps arepossible. Described below are other methods and devices for the machineof the present invention, without intending to be limiting.

[0218] Forming a head a sleeve, for example, may be done by a variety ofdifferent methods. For example, a previously formed head may be joinedwith a thermoplastic sleeve by heat welding or sonic welding the sleeveand the head together. Or a head may be formed from the end of thethermoplastic sleeve by the process disclosed in U.S. Pat. No.5,069,856, assigned to the assignee of the present invention and theprocess of which is incorporated herein. Further a head may be formed byinjection blow molding or blow molding a head directly onto a sleeveloaded onto a mandrel on the indexing device.

[0219] Still further a head may be molded in a reusable closure means orcap. An example of molding in a reusable closure means is describedco-pending application “Method of Forming a Headed Thermoplastic Tubewith a Reusable Closure” assigned to the assignee of the presentinvention and incorporated by reference herein. Therefore, depending onthe finished product desired any number of different methods may be usedto form a head on the end of thermoplastic sleeve.

[0220] An example of forming a head in a in a reusable closure means isas follows: A method of forming a tube from an thermoplastic extruded,stretched sleeve is provided by positioning a sleeve over a formingmandrel with an exposed portion of the sleeve extending beyond a headforming end of the mandrel. The inner wall surface of the exposedportion of the thermoplastic sleeve is heated to a temperature above theglass transition temperature of the thermoplastic material to render theinner surface area molten, while maintaining the outer surface of thesleeve below the glass transition temperature so as to provide supportfor the exposed portion of the sleeve and retain the cylindrical shapethereof. The heated exposed portion is then shaped into a conical shape,such as by directing hot air against the outer surface thereof. Pressureis then applied to the conical shaped exposed portion of thethermoplastic extruded sleeve by contacting the exposed portion with areusable closure means to form a headed thermoplastic tube. The pressureapplied to the conical shaped exposed end portion forces the same into areusable closure means for the tube held in place by a holding orgripping member.

[0221] The reusable closure means used in this method functions as amold for the neck or a mold for both the shoulder and neck when forminga head on the thermoplastic sleeve and a reusable cap for the finishedthermoplastic tube. The reusable closure means is made of a materialincompatible with the thermoplastic sleeve material such that when themolten end of the thermoplastic sleeve is pressed into the reusableclosure means, the reusable closure means does not melt or stick to themolten preform.

[0222] Yet a further method for forming a head on a tube involvesrotating a sleeve while heating it. An example of this method isdescribed co-pending application “Method of Forming a HeadedThermoplastic Tube” assigned to the assignee of the present inventionand incorporated by reference herein. A thermoplastic extruded,longitudinally stretched sleeve is positioned over a forming mandrelwith an exposed portion of the sleeve extending beyond a head formingend of the mandrel. The mandrel is then rotated while the sleeve isheated. The rotation provides for even heat distribution at the locationwhere the heat is applied. The rotation of the sleeve is stopped andpressure is then applied to the conical-shaped, exposed portion of thethermoplastic, extruded sleeve by contacting the exposed portion with amolding die to form a headed thermoplastic tube.

[0223] An alternate way to form a head is to weld a preformed head ontoa sleeve by high frequency sound. Sonic weld station, illustrated inFIG. 26, may be substituted for preheat (B), heat (C) and mold (D)stations of machine 85 as an alternative station for forming a head on asleeve.

[0224]FIG. 26 illustrates a preferred sonic welding station for weldingby high frequency sound, a preformed head to a thermoplastic sleeve.Sonic weld station has a sonic welder attached to a movable carriage andmeans to mount the device and carriage to the frame of the machine ofthe present invention, like mounting ring 13 of FIG. 1. The carriagebrings the sonic welder into proximity with a sleeve.

[0225] In FIG. 26 carriage 267 has a frame or housing 269 which providesa top surface 271 for securing sonic welder 273 and an interior cavity275, under top surface 271, for mounting or locating a means to impartmotion to carriage 267, like an air cylinder 277. Carriage 267 ispneumatically driven by an air cylinder 277, supplied with air by lines279. Carriage 267 is slidably mounted on rods 281 which are linear guidemeans. Each rod 281 is secured by a bracket 283 at each end to mountingplate 285.

[0226] The sonic weld station operates as follows: when a sleeve loadedand positioned on mandrel 87 of machine 85, for example, is aligned withsonic welder 273, carriage 267 advances along rods 281 to bring sonicwelder 273 in proximity to the sleeve. As carriage 267 advances, anexposed portion of the sleeve enters and passes into sonic welder 273which welds a preformed head to the sleeve by means of high frequencysound. Sonic welder 273 is connected to supply and control line 287which supplies the input necessary for sonic welder 273 to operate.

[0227] Sonic welder 273 is mounted in housing 289 which is attached totop surface 271 of carriage 267. Carriage 267 retracts by the action ofair cylinder 277 to its original position, out of the path of motion ofmandrel 87, after a preselected period of time. The result of themanufacturing step is that a preformed head is welded onto a sleeve toform a tube.

[0228] The machine of the present invention is also useful forcompleting the manufacturing of tubes if, for example, the sleeves havebeen partially processed at another location. Preprinted sleeves may beloaded onto a machine of the present invention and the manufacturing oftubes may be completed by forming a head on the sleeves and performingany desired finishing step like, tab sealing, capping or torquing.

[0229] 7) Large Scale Manufacturing

[0230] The machines of the present invention may be arranged into smallgroups. When arranged into small groups or “production cells,” space,labor and raw material input can be saved. One production cell typicallycontains six machines each of which can manufacture headed, sealed,capped and decorated tubes from blank thermoplastic sleeves. A singlecell has a total output equivalent to a single conventional processline.

[0231] A manufacturing and packing plant using machines of the of thepresent invention is an efficient arrangement of a plurality ofproduction cells connected by a common transportation line. Theefficient arrangement of cells leads to further decreases in labornecessary to operate a number of production cells. An example of thepreferred manufacturing plant is described in co-pending application“Plant for Manufacturing and Packing Thermoplastic Tubes” assigned tothe assignee of the present application and incorporated by referenceherein.

[0232] IV. Manufacturing with a Programmable Logic Controller

[0233] A PLC device may be added to the machine of the present inventionfor the purpose of controlling the entire machine including the variousmanufacturing stations. In conventional process lines some of themanufacturing equipment is PLC controlled. However machine feedbackcontrol to control all aspects of a manufacturing step, product qualitycontrol and product feedback control and total mechanical control oversleeves and tubes have not been feasible. Such PLC control is almostimpossible in conventional processing lines because large processinglines handle several hundred thermoplastic articles at a time and thereis no systematic method for keeping track of individual articles andcontrolling the same on the conventional machines.

[0234]FIG. 1 illustrates one embodiment of a machine of the presentinvention, with each manufacturing station connected to a PLC device, asindicated by the dashed lines. The PLC device can perform a variety offunctions: A PLC device may be employed to control, by turning on orturning off, each manufacturing station along a manufacturing path. APLC device can control the inputs needed for each manufacturing station.For example, a PLC device can control the heating temperature of thepreheat and heat stations. The PLC can control the speed of eachmanufacturing station and the speed of the entire manufacturing machine.

[0235] Process control for the machine of the present invention involvescontrolling the operation of individual manufacturing stations alone orin combination with other manufacturing stations around the closedmanufacturing path. The operation of the manufacturing stations may bebased on information gathered from sensors obtaining information aboutthe operation of each manufacturing station itself, sensors obtaininginformation about the quality of the thermoplastic tubes produced, orinformation obtained from both the operation of each of themanufacturing stations and the quality of the thermoplastic tubesproduced. Examples of the sensors that may used are listed below inTable I: TABLE I SENSOR TYPE MEASUREMENT 1. Load sensor Electric EyeConfirm Load 2. Preheater Air Flow Flow Meter Air Flow Rate 3. PreheaterTemperature Thermocouple Air Temperature 4. Sleeve Temperature InfraredSensor Sleeve Temperature 5. Heater Air Flow Flow Meter Air Flow Rate 6.Heater Temperature Thermocouple Air Temperature 7. Sleeve TemperatureInfrared Sensor Sleeve Temperature 8. Mold Temperature ThermocoupleCooling Water Temperature 9. Mold Flowmeter Flow Meter Cooling WaterFlow Rate 10. Treater Confirmation Electric Eye Confirm Corona Arc 11.Treater Amperage Ammeter Treatment Level/ Pinhole Detection 12. LabelSensor Labeler Confirm Label Application Controller 13. Printer PrintController Confirm Print Application 14. Cure Sensors Voltmeter CureUnit Voltage Ammeter Cure Unit Amperage Thermocouple Cure UnitTemperature 15. Inspection System Vision System Confirm Heading & Print(Camera) Quality 16. Coating Sensor Level Sensor Confirm CoatingPretense 17. Cure Sensors Voltmeter Cure Unit Voltage Ammeter Cure UnitAmperage Thermocouple Cure Unit Temperature 18. Inspection System VisionSystem Confirm Heading, Print, & (Camera) Coating Quality 19. Tab SealThermocouple Punch Temperature Electric Eye Tab Seal Pretense 20.Inspection System Vision System Confirm Heading, Print, (Camera) Coat, &Tab Seal Quality 21. Capping Electric Eye Confirm Cap Pretense 22.Torque Torque Meter Confirm Applied Torque 23. Inspection System VisionSystem Confirm Heading, Print, (Camera) Coat, & Capping Quality 24.Eject Electric Eye Confirm Tube Removal 25. Reject Electric Eye ConfirmTube Removal 26. Confirmation Microswitch Confirm Tube Removal

[0236] After gathering selected information from sensors in variouslocations around the closed manufacturing path the process controlmethod would continue as follows: a signal would be generatedcorresponding to the selected information gathered from each of themanufacturing stations. The signals generated would be imputed into aPLC device and with the use of the signals, the operation ofcorresponding manufacturing stations would be controlled by the PLCdevice.

[0237] In a typical example of the control system, the PLC device willcompute all of the “decisions” regarding the operation of themanufacturing machine based on information received from sensors on eachmanufacturing station. This provides the manufacturer with theopportunity to monitor the activities that occur at each station andidentify any abnormalities in the product or process immediately.Defective products can identified instantly and downstream stations maybe shut off to conserve process resources. The defective products canthen be segregated at a reject station on the machine.

[0238] The PLC device in combination with the manufacturing stations,sensors and indexing table can collect, on a continuous basis, the type,degree and frequency of failures of the product or process. This canprovide a profile of effectiveness of equipment and each process step.Reports can be generated about process and quality of the product.

[0239] Further process control would include establishing setpoints forcontrolling the operation of each manufacturing station and with the useof the generated signals, as previously mentioned, the operation of eachmanufacturing stations could be controlled within the establishedsetpoints. Setpoints,may be established automatically after the machineinvention has reached steady state. The PLC device would automaticallyestablish upper and lower boundary setpoints based on the operation ofthe machine at steady state over a period of time. Alternatively, thesetpoints may be predetermined and simply programmed into the PLCdevice.

[0240] The signals generated from the sensors located on themanufacturing stations themselves or around the closed manufacturingpath may be mechanical, electronic, optical, pneumatic, hydraulic orcombinations thereof. Any type of signaling means may be used tocommunicate among the sensors and the PLC device.

[0241] Another method for controlling the thermoplastic tubemanufacturing machine is the following: marking each tube withindividual indicia; sensing selected information from tubes marked withindividual indicia; generating a signal corresponding to each ofmanufacturing stations based on selected information; inputting signalsto the PLC device; and with use of signals, controlling the operation ofa corresponding manufacturing station with the PLC device.

[0242] Each thermoplastic tube may be marked with an individual indiciafrom a computer controlled printing device, like the inkjet printer ofFIG. 19, which has the capability of uniquely marking each tube. Thenselect information may be gathered from the tubes marked with anindividual indicia by a sensing means. Further signals may be generatedbased on the selected information gathered. The signals may be inputinto a PLC device and with the use of the signals, the operation ofcorresponding manufacturing stations may be controlled. This type ofprocess control is the use of a feedback loop based on individuallymarked tubes to indicate to a PLC device to make or stop producingcertain types, kinds, or varieties of tubes.

[0243] For example if 15,000 tubes of three different lots of 5,000tubes per lot, all having the same diameter, are to be manufactured,then a feedback loop based on marked indicia on each tube would allow amanufacturer to manufacture the 15,000 tubes continuously withoutstopping the machinery. After 5,000 tubes of one type have beenmanufactured and an indicia on tube number 5,000 was identified bysensing means, like a vision camera, then a signal could be generatedbased on this indicia, and sent to a PLC device. With the use of thissignal, the PLC device may then control the operation of the machine,with a subsequent command control signal, to change production, likechanging the decoration step or the finishing steps, to manufacture thesecond lot of 5,000 tubes. The process could be repeated for the thirdlot of 5,000 tubes. By this feedback control method based on markingeach tube with an individual indicia, a manufacturer may operate amachine of the present invention with zero down time.

[0244]FIG. 27 is a schematic representation a machine 291 of a thirdembodiment invention having indexing table 293, 20 mandrels 295 mountedthereon and 20 manufacturing stations labelled (A) through (T),corresponding to each of 20 mandrels, all connected to PLC device 297.Indexing table 293 rotates counterclockwise in this embodiment inresponse to indexer 299 (FIG. 28). The 20 stations and correspondingprocess steps of this embodiment are as follows: (A) load, (B) preheat,(C) heat, (D) mold, (E) treatment, (F) label, (G) print, (H) cure, (I)inspect, (J) coat, (K) cure, (L) inspect, (M) tab seal, (N) inspect, (O)cap, (P) torque, (Q) inspect, (R) unload, (S) reject and (T)confirmation. FIG. 28 is a perspective view of FIG. 27, showing only themain components of manufacturing stations (A) through (T). Themanufacturing stations of machine 291 which are common to machine 85 ofthe second embodiment are physically the same as the manufacturingstations of machine 85.

[0245] In addition to adding sensors to the stations of themanufacturing path illustrated in FIGS. 27 & 28, additional stationshave been added. Four inspection stations (I), (L), (N) and (Q) havebeen added at different locations along the closed manufacturing path.Product inspection may be performed by any known method. FIG. 29illustrates any one of inspection stations (I), (L), (N), and (Q). Aninspection station is typically a vision camera which has the ability toinspect product quality. The inspection station in FIG. 29 isillustrated as having a vision camera 301 receiving input and sendingoutput signals to PLC device 297 (FIG. 27) through control and powerline 303. Vision camera 301 is mounted on a bracket 305 which may beadjustable and mounted on a frame or mounting ring of the machine, likemounting ring 13 of machine 1 in FIG. 1. Inspection stations canidentify and monitor individual indicia on sleeves and tubes so marked.

[0246] Preferred rejection station (S) is illustrated in FIG. 31. It ismechanically the same as unload station (N) of the embodiment on FIG.25. Pneumatic stripper 307, with stripper plate 309, is driven back andforth along guide arm 311 by air cylinder 313, supplied with air by airlines 315, positioned behind guide arm 311 on a mounting bracket 317.Mounting bracket 317 is further mounted on a mounting plate, likemounting plate 103 of FIG. 12, which is attached to a mounting ring orequivalent, like ring 13 of FIG. 1. Stripper 307 removes defective tubesfrom machine 291 based on command signals from PLC device 297.

[0247] Reject station (S) operates as follows: a stripper plate 309slides back and forth in contact with mandrel 295 unloading any tube onmandrel 295. Once the thermoplastic tube has been removed, stripper 307and stripper plate 309 return to their original position.

[0248] Confirmation station (T), illustrated in FIG. 30, is for thepurpose of confirming that a tube has been removed by either unloadstation (R) or rejection station (S) from mandrel 295. The confirmationstation (T) in FIG. 30 is shown as having a sensor arm 319 receivinginput and sending output signals to a PLC device (not shown) throughcontrol and power line 321. Sensor arm 319 is mounted on a bracket 323which may be adjustable (not shown). Confirmation station (T) canalternatively be an electronic or vision means for performing tubeconfirmation.

[0249] V. Manufacturing Example

[0250] A 10 mandrel machine having 7 manufacturing stations, in order:load, heat, mold, treat, print, cure, and unload, was used tomanufacture headed and decorated thermoplastic tubes from longitudinallystretched and extruded thermoplastic sleeves. Headed tubes of highquality were produced at a rate of 13 tubes per minute (tubes/min). Thefollowing process parameters were used to achieve this output:

[0251] The machine used a 10 mandrel aluminum indexing tableapproximately 16 inches in diameter set at a counterclockwise rotationspeed of 1.3 revolutions/min. The load station was a pneumatic push-pulldevice which loaded thermoplastic sleeves from a chain conveyor ontoholding mandrels on the indexing table at a rate of 13 sleeves/min. Eachsleeve was loaded onto a mandrel so that approximately 0.5 inch ofsleeve extended beyond the end of the mandrel. The sleeve was thentransported downstream to the second station in the manufacturing path,the heat station.

[0252] The heat station had a hot air heating probe mounted behind acooling bushing on a slidable pneumatic carriage. The portion of thesleeve extending beyond the end of the mandrel was heated by air flowingat a rate of 40 cubic cm/second (cc/s) at a temperature of about 720°F., for approximately 3 seconds. The carriage was set at a speed ofapproximately 0.5 cycle/s.

[0253] Following the retraction of the carriage, the heatedthermoplastic sleeve was indexed one position downstream to the moldstation. The mold station was mounted adjacent the heat station on thesame slidable pneumatic carriage. The carriage advanced to contact amold die with the molten preform mass at the end of the heated sleeve.The contact time was about 3 seconds and the mold die temperature wasroom temperature.

[0254] The thermoplastic sleeve, now a thermoplastic tube, was nexttransported to a corona treatment unit. The treatment of thethermoplastic tube occurred for approximately 2 seconds. Followingsurface treatment, the tube was indexed further downstream to a coatstation where a coating was applied to the tube surface. A thin coatingwas applied around the tube by the application rollers of the station.Following this, the thermoplastic tube was cured by hot air at the curestation, at a temperature of 300° F. from an industrial blower.

[0255] After hot air curing the finished thermoplastic tube was unloadedfrom the machine. The total processing time for one tube was 4.6 secondsand the machine produced tubes at a rate of 13 tubes/min. The tubesproduced were finished commercially viable tubes of high quality andwere later capped to produce headed thermoplastic tubes which weredecorated and capped.

[0256] Producing tubes which have an adhesive label on theaforementioned machine was less complicated. Instead of treating andcoating on the machine, a label station was added to apply labels to thethermoplastic tube. All of the parameters and stations previouslymentioned were the same except for the addition of the label station.Labeled commercially viable tubes were produced at a rate of 13tubes/min.

[0257] VI. Further Embodiments

[0258] The machine of the present invention is flexible and may beadapted to manufacture thermoplastic tubes of various lengths,thicknesses, weights, diameters, shapes, and complexity. In order adapta machine to manufacture tubes of a specific diameter, the indexingtable is fitted with appropriately sized mandrels and the manufacturingstations are adapted to work on the specific diameter thermoplasticsleeves. Adaptations for the stations may include adjusting the positionof the station relative to the mandrel, changing the size of a bushingorifice, or changing the size of a component of a particular station.Additionally the machine of the present invention may altered toaccommodate different transportation means—different indexing devices,like an indexing drum.

[0259] The machine of the present invention is flexible to accept avariety of manufacturing processes on the same machine. Differentmanufacturing processes are created by the number, sequence and varietyof manufacturing stations around the closed manufacturing path. Thestations around the path may be changed in a number of ways including:adding or removing manufacturing stations, turning on or turning offstations and rearranging the order of the stations.

[0260] The following figures will illustrate some of the possibleconfigurations of a machine of the present invention which result in avariety of manufacturing methods.

[0261]FIG. 32 illustrates a machine 325, shown without a frame, havingan indexing table 327 which rotates counterclockwise in response toindexer 329; 6 manufacturing stations: load (A), preheat (B), heat (C),mold (D), label (E) and unload (F); 6 mandrels 331; and a manufacturingpath capable of 6 process steps, namely: loading, preheating, heating,molding, labeling and unloading. FIG. 33 is a front view of the closedmanufacturing path.

[0262] Even in the embodiment of FIG. 32, the manufacturing path may berearranged so that labelling is performed prior to heating and molding.To do this the label (E) station would be moved to a mandrel upstream ofthe preheat (B) station. The advantage of a machine with sixmanufacturing stations and six mandrels is that it is compact, easy tooperate, simple in design and consumes small amounts of power, air,electricity and other inputs.

[0263]FIG. 34 illustrates a machine 333, shown without a frame, havingan indexing table 335 which rotates counterclockwise in response toindexer 337; 6 manufacturing stations: load (A), preheat (B), heat (C),mold (D), label (E) and unload (F); 10 mandrels 339; and a manufacturingpath capable of 6 process steps, namely: loading, preheating, heating,molding, labeling and unloading. FIG. 35 is a front view of the closedmanufacturing path. Machine 333 has 4 expansion mandrels for theaddition of manufacturing stations in the future. Machine 333 has thepotential to accept more manufacturing process methods than machine 325of FIG. 32 because of the expansion mandrels.

[0264]FIG. 36 illustrates a machine 341, shown without a frame, havingan indexing table 343 which rotates counterclockwise in response toindexer 345; 10 manufacturing stations: load (A), preheat (B), heat (C),mold (D), label (E), inspect (F), inspect (G), unload (H), reject (I)and confirm (J); 14 mandrels 347; and a manufacturing path capable of 10process steps, namely: loading, preheating, heating, molding, labeling,first inspecting, second inspecting, unloading, rejecting andconfirming. FIG. 37 is a front view of the closed manufacturing path.Four expansion mandrels allow for the addition of other manufacturingstations as well as the flexibility to rearrange the manufacturing pathillustrated in FIG. 36.

[0265]FIG. 38 illustrates a machine 349, shown without a frame and shownwith only partial views of the manufacturing stations, having anindexing table 351 which rotates counterclockwise in response to indexer353; 6 manufacturing stations: load (A), preheat (B), heat (C), mold(D), label (E) and unload (F); 20 mandrels 355; and a manufacturing pathcapable of 6 process steps, namely: loading, preheating, heating,molding, labeling and unloading. If space is not a constraint, machineswith larger indexing tables may be built for the future potential ofmanufacturing expansion.

[0266] The machine 357 illustrated in FIG. 39 is similar to that of FIG.38, having five additional manufacturing stations: inspect (F), inspect(G), unload (H), reject (I) and confirm (J) stations.

[0267]FIG. 40 illustrates a machine 359, shown without a frame, havingan indexing table 361 which rotates counterclockwise in response toindexer 363; 9 manufacturing stations: load (A), preheat (B), heat (C),mold (D), label (E), tab seal (F), cap (G), torque (H) and unload (I); 9mandrels 365; and a manufacturing path capable of 9 process steps,namely: loading, preheating, heating, molding, labeling, tab sealing,capping, torquing, and unloading. FIG. 41 is a front view of the closedmanufacturing path. This manufacturing machine is compact in size andhas the ability to manufacture headed, labelled, tab sealed, capped andtorqued thermoplastic tubes.

[0268]FIG. 42 shows a machine 371 of the present invention having anindexing table 367 upon which is mounted a plurality of oval formingmandrels 369, for holding oval thermoplastic sleeves to form ovalthermoplastic tubes. Oval thermoplastic tubes are formed in amanufacturing path, schematically represented, having 9 manufacturingstations and corresponding process steps: load (A), preheat (B), heat(C), mold (D), treat (E), print (F), cure (G), cap (H) and unload (I).FIG. 43 is a front view of indexing table 367 with oval mandrels 369.

[0269]FIG. 44 illustrates a tooling change for a machine 373 of thepresent invention capable of manufacturing twice as many thermoplastictubes. Pairs of mandrels 375 are positioned side by side with only asmall gap between them on indexing table 377 which rotates in responseto indexer 379 so that the manufacturing stations can work on twothermoplastic articles simultaneously. The manufacturing stations mayneed to be altered slightly to accommodate two articles. FIG. 45 is afront view of machine 373.

[0270] Alternatively instead of an indexing table, an indexing drum 381(FIG. 46) may be used as the indexing device in a machine 383 of thepresent invention, shown without complete frame (FIG. 47). Indexing drum381 is a drum with the cross-sectional shape of a cylinder or polygonhaving a plurality of means for supporting thermoplastic sleeves, i.e)mandrels 385 around the outside length of the drum. Manufacturingstations for working on thermoplastic sleeves loaded on mandrels 385 areoriented accordingly so they can perform manufacturing steps on thethermoplastic sleeves (FIG. 47).

[0271] Machine 383 rotates clockwise in response to an indexer (notshown) around the following 8 manufacturing stations and correspondingmanufacturing steps: load (A), heat (B), mold (C), treat (D), print (E),cure (F), cap (G) and unload (H), similar to like stations previouslydescribed for machine 85 of the second embodiment of a machine of thepresent invention. The manufacturing stations (A)-(H) are mounted on amounting ring 387 which is further mounted on a frame of the machine383. For clarity, FIG. 47 shows only manufacturing stations (A)-(H) andmounting ring 387 for the first set of mandrels 385 on indexing drum381. In production, mounting ring 387 would extend the length ofindexing drum 381 and all stations (A)-(H) would be repeated for thecorresponding mandrels 385. Sleeves would be supplied to all loadstations by a chute or transportation means (not shown).

[0272] One advantage of a indexing drum is that more thermoplastic tubesmay be produced in a compact space by simply extending the indexing drumand adding more mandrels for supporting thermoplastic sleeves andadditional manufacturing stations mounted on a mounting ring. Thedescription of the process method and process control of a machine ofthe present invention herein applies to a machine having an indexingdrum.

[0273] While there has been illustrated and described severalembodiments of the present invention, it will be apparent that variouschanges and modifications thereof will occur to those skilled in theart. It is intended in the appended claims to cover all such changes andmodifications that fall within the true spirit and scope of the presentinvention.

What is claimed is:
 1. An apparatus for converting thermoplastic sleevesinto thermoplastic tubes, comprising: an indexing device rotatable abouta shaft; means for supporting sleeves mounted on said indexing devicefor advancement along a closed path in response to relative rotation ofsaid indexing device in a predetermined direction; a frame for mountingsaid indexing device and a plurality of manufacturing stations, saidplurality of manufacturing stations further comprising: means forloading said sleeves onto said supporting means in a first location ofsaid closed path; means for forming a head on said sleeves to form tubesin a second location of said closed path downstream of said firstlocation; and means for unloading said tubes from said supporting meansin a third location of said closed path downstream of said secondlocation positioned between said second and first locations.
 2. Theapparatus according to claim 1 wherein, said means for loading sleevesonto said supporting means is a member selected from the groupconsisting of a push rod driven by an air cylinder; a push rod driven bya cam driver; an advancing and retracting linear actuator; a crankmotion device and a servo-motor driven push rod.
 3. The apparatusaccording to claim 1 wherein, said means for forming a head on saidsleeve is a member selected from the group consisting of a heater and amold die; a sonic welder and a heat welder.
 4. The apparatus accordingto claim 1 wherein, said means for unloading said tubes from saidsupporting means is a member selected from the group consisting of astripper driven by an air cylinder; a stripper driven by a cam driver;an advancing and retracting linear actuator; an air blower; a crankmotion stripper and a servo-motor driven stripper.
 5. The apparatusaccording to claim 1 wherein, said apparatus further comprises a PLCdevice connected to said indexing device, said loading means, said headforming means and said unloading means.
 6. The apparatus according toclaim 1 , wherein said indexing device is a member selected from thegroup consisting of an indexing table and an indexing drum.
 7. Anapparatus for converting thermoplastic sleeves into thermoplastic tubes,comprising: an indexing device rotatable about a shaft; means forsupporting sleeves mounted on said indexing device for advancement alonga closed path in response to relative rotation of said indexing devicein a predetermined direction; a frame for mounting said indexing deviceand a plurality of manufacturing stations; said plurality ofmanufacturing stations further comprising: means for loading saidsleeves onto said supporting means in a first location of said closedpath; means for forming a head on said sleeves to form tubes in a secondlocation of said closed path downstream of said first location; meansfor decorating said tubes in a third location of said closed pathdownstream of said second location; and means for unloading said tubesfrom said supporting means in a fourth location of said closed pathdownstream said third location positioned between said third and firstlocations.
 8. The apparatus according to claim 7 wherein, said means forloading sleeves onto said supporting means is a member selected from thegroup consisting of a push rod driven by an air cylinder; a push roddriven by a cam driver; an advancing and retracting linear actuator; acrank motion device and a servo-motor driven push rod.
 9. The apparatusaccording to claim 7 wherein, said means for forming a head on saidsleeve is a member selected from the group consisting of a heater and amold die; a sonic welder and a heat welder.
 10. The apparatus accordingto claim 7 , wherein said means for decorating is at least one memberselected from the group consisting of labeler; offset printer; inkjetprinter; screen printer; letter printer; computer printer; coater;embosser and etcher.
 11. The apparatus according to claim 7 wherein,said means for unloading said tubes from said supporting means is amember selected from the group consisting of a stripper driven by an aircylinder; a stripper driven by a cam driver; an advancing and retractinglinear actuator; a crank motion stripper and a servo-motor drivenstripper.
 12. The apparatus according to claim 7 wherein, said apparatusfurther comprises a PLC device connected to said indexing device, saidloading means, said head forming means, said decorating means and saidunloading means.
 13. The apparatus according to claim 7 , wherein saidindexing device is a member selected from the group consisting of anindexing table and an indexing drum.
 14. An apparatus for convertingthermoplastic sleeves into thermoplastic tubes, comprising: an indexingdevice rotatable about a shaft; means for supporting sleeves mounted onsaid indexing device for advancement along a closed path in response torelative rotation of said indexing device in a predetermined direction;a frame for mounting said indexing device and a plurality ofmanufacturing stations; said plurality of manufacturing stations furthercomprising: means for loading said sleeves onto said supporting means ina first location of said closed path; means for forming a head on saidsleeves to form tubes in a second location of said closed pathdownstream of said first location; means for decorating said tubes in athird location of said closed path downstream of said second location;means for finishing said tubes in a fourth location of said closed pathdownstream of said third location; and means for unloading said tubesfrom said supporting means in a fifth location of said closed pathdownstream said fourth location positioned between said fourth and firstlocations.
 15. The apparatus according to claim 14 , wherein said meansfor finishing said tubes is a member selected from the group consistingof a tab sealer; a capping device; a torquing device and an inspectingdevice.
 16. The apparatus according to claim 14 , wherein said indexingdevice is a member selected from the group consisting of an indexingtable and an indexing drum.